Apr 26, 2023

From autonomous mobile robots to real-time tracking systems, technology developers have reshaped the warehousing landscape with a myriad of automated solutions. Designed for speed and ease of use, modernized enterprise technology promises to accelerate order throughput without compromising accuracy. With 82% of warehouses projecting significant inventory growth and another 86% planning to expand warehouse facilities, automated solutions provide crucial speed to create adaptable systems. However, failure to properly outline a modernization plan can lead to multiple stressors such as:

• Long training times
• Device failure from misuse
• Connectivity issues within the warehouse
• Higher operational costs
• Unnecessary acquisition costs 
• Workflow disruptions and downtime
  
  

It is estimated that only 35% of warehouses truly know where and how to start optimizing operations. Maturity models and roadmaps have become useful tools to assess operational levels and track growth opportunities, yet proactive planning is still foundational to best implement enterprise systems. In gaining a clear picture of your current systems’ efficiencies, solution providers can design a custom solution that grows alongside your operations to meet future challenges without reframing your entire facility. To accomplish this, experts recommend evaluating modernization needs with the following questions:

1. Which supply chain challenge is impacting your operations the most?
2. How are you gathering data for decision-making?
3. What immediate goals do you expect from your solution?
4. What is the comfort level of my workforce regarding technology?
5. Can you repurpose your current technologies today and tomorrow?

Question 1: Which supply chain challenge is impacting your operations the most?  

Outside challenges have long pressured warehouses to fulfill orders faster under shifting compliances and standards. Nevertheless, some challenges are more pertinent than others depending on your inventory. For example, distribution centers handling apparel must be prepared to accommodate a 20.8% return rate. Similarly, cold chain facilities must adhere to several compliance codes as they move food and pharmaceutical products. While several challenges may be impacting your business, try to pinpoint a handful of issues to resolve. To do this, try matching your constraints to probable causes such as:

• Downtime at the loading dock stemming from lack of personnel.
• Recurrent inventory loss coming from lack of trackable visibility.
• Increase in recalls affecting multiple serial numbers.
• Shipping delays persisting past holiday peak seasons.
• Sudden stockouts slipping by unnoticed due to poor team communication.

In assessing major obstacles, you can gather measurable performance indicators to ensure your solution’s success. 

Question 2: How are you gathering data for decision-making?

Most modern warehouses are used to operating on a top-down model where administrators determine which products to replenish based on communication with other members of the supply chain. However, the e-commerce boom has virtually shifted this model by creating sudden demand spikes and shortening fulfillment workflows to mere hours. Warehouses operating with Just-in-Time replenishment are now transitioning to a “Just-in-Case” model where potential high-demand products are stored preemptively to mitigate stockouts. To avoid unnecessary overstocking, data must be gathered in real-time from the picking aisles. When monitoring stock levels, warehouse leaders can convert gathered data into:

• Future purchasing patterns 
• Personalized shopping suggestions for e-commerce customers
• Targeted view of possible workflow mistakes 
• Scheduled replenishment cycles 

Question 3: What immediate goals do you expect from your solution?

Obviously, businesses expect increased ROI and diminished operating costs, but these goals may take time to unravel following implementation. Nevertheless, your solution provider should be able to outline possible key performance indicators (KPIs) like:

• Rate of fulfillment
• Order accuracy rates
• How many orders are picked per worker
• Frequency of stockouts 
• Actionable insights delivered through your system

While different solutions may create unique benefits, automated data capture and RFID scanning have been shown to boost inventory visibility to 99.9% when replacing manual systems. Moreover, in measuring KPIs during piloting and training, your team can adjust solutions to tackle secondary issues, establishing scalability before challenges disrupt your workflows. 

Question 4: What is the comfort level of my workforce regarding technology?

Another disruptive factor to consider is your workforce’s comfort level with novel technologies. This is where a clear picture of your warehouse’s maturity level can come in handy since workers using fewer digital devices may not be ready to adopt predictive analytics and RFID. Even the most innovative technology will be a hindrance if your front-line workers aren’t on board with your modernization plan. Zebra’s latest vision study shows that three-quarters of warehouse decision-makers involve warehouse associates in the procurement process.

Although every modernization solution comes with a learning curve, certain technology features help diminish adoption rates for faster productivity. For example, Zebra’s latest generation of enterprise mobility leverage:

• Android for Enterprise – Because it already runs on over 80% of consumer devices, Android provides an unmatched level of familiarity coupled with enterprise-ready security patches and encryption. Moreover, Android’s open application ecosystem allows IT teams to develop and run familiar apps on Android devices for better ease of use. 
• Rugged Touchscreens – While better than pen-and-paper systems, keyboard devices still leave room for possible data entry errors. On the other hand, touchscreens bolster accuracy with easy-to-read and user-friendly interfaces. Furthermore, Zebra’s All-Touch TE application converts green-screen apps into touchscreen interfaces, permitting workers to continue executing familiar workflows on durable touchscreens.
• Push-to-Talk Communication – Additional two-way walkie-talkies have been commonplace in most warehouses, yet they add an extra device for workers to carry and IT teams to maintain. To safeguard real-time communication within the four walls, handheld computers are now equipped with push-to-talk and direct messaging software to deploy alerts, assign tasks, and notify teams of incoming orders and stock levels – all through the same handheld scanning and sharing your data. 
• Embedded Data Capture – Lastly, from handheld computers to enterprise tablets, mobile devices have also been paired with intelligent scanners and PRZM imaging to transcribe data immediately into the WMS. This reduces the need to service multiple scanners while reducing the amount of heavy equipment your teams must carry.      

Question 5: Can you repurpose your current technologies today and tomorrow?

It’s been mentioned previously; however, scalability is crucial to surviving in today’s volatile supply chains. Change is the only constant businesses can expect in the digital age. As a result, long-lasting modernization strategies should seek to maximize usage from your devices through tailored connectivity networking and a reliable support system. Verify scalability before deployment by selecting:

• Operating systems with continuous updates and patches
• Open digital platforms that aggregate new workflows
• Versatile hardware to execute multiple tasks
• Technologies prioritizing real-time operational visibility 

Modernization isn’t an Option. It’s a Necessity.

Next-evolution technologies such as predictive analytics and robotics are only expected to increase in popularity across the globe. As a matter of fact, research indicates that 8 in 10 warehouse decision-makers already see improvements with deploying novel technologies such as autonomous mobile robots (AMRs), yet to reach that level of maturity, certain digitization steps must be taken first. Failure -or delay- to do so may set businesses back, hindering profitability and customer satisfaction. 

As an experienced leader in warehouse modernization, Heartland works alongside leading technology players like Zebra to customize optimization plans for seamless implementation and scalability. Walk through these preliminary questions with our specialist team to evaluate your warehouse’s maturity level and project a growth plan that sets your teams up for success.